Composite materials reinforced with ceramic waste and matrix of unsaturated polyester for applications in the automotive industry

Abstract

In the present investigation an alternative of recycling was evaluated for the residues derived from defective pieces of the ceramic industry, harnessing them as reinforcement in composite materials for the manufacture of parts used in the automotive sector. Sintered clay microparticles to 10% p/p were mixed in an unsaturated polyester resin matrix, through the cast molding technique. Bending tests were performed that showed an elastic-linear behavior, typical of a fragile material. The structure was analyzed through scanning electron microscopy, checking the fragile failure mechanism and a good dispersion of the microparticles. A simulation was carried out with the finite element method, for the design of a motorcycle brake lever, with results that demonstrate a better distribution of stresses and reduction in mass with respect to the original part. Finally, a prototype brake lever was manufactured using computationally validated geometry.